3 KPIS TO REINFORCE ACCOUNTABILITY Sonic advises quarterly FOD/tool-control drills with timed “missing tool” scenarios and so-called “5S audits,” a systematic review methodology that focuses on five criteria: sort, set in order, shine, standardize and sustain. It’s also important to reinforce tool-control accountability by using key performance indicators, such as: • Measure lost-tool rate per 1,000 labor hours • Track audit pass percentage and average time-tolocate • Capture monthly tools in-calibration exception count ALIGN THESE 3 PILLARS OF TOOL CONTROL Continuous improvement is the baseline of aircraft maintenance, and tool control is no different. According to Chwan, the most successful flight operations start by aligning three pillars: 1. Culture: Define and reinforce a “no-exceptions” mindset around tool accountability. 2. Process: Standardize tool issue, return, calibration and inspection steps. 3. Technology: Deploy right-sized control systems, from the basic custom foam inserts and shadow boards to fully automated aircraft tool control systems with enterprise data integration. Drawer shadowing, inventory spreadsheets, camera systems and tracking software are all hugely beneficial. However, at the end of the day, “each individual is responsible for managing their own tools,” said Bradshaw. It is imperative that every technician and quality control inspector remains vigilant when it comes to tool reclamation “so much so that it eventually becomes ingrained in the aircraft return-to-service process.” ‘ABSOLUTE BEST’ TOOL INVENTORY METHOD “The shadowed toolbox is probably the absolute best way to do a personal tool inventory,” said Peebles, a 2022 NBAA Business Aviation Top 40 Under 40 Award recipient. When fatigue sets in, the ability to glance at the shadowed toolbox is easy. But if a tool is not present in its shadowed spot, it is easily recognized as missing, he said. The bottom line is, whether you’re using a complex system or a simple method, a safe and effective aircraft maintenance tool program boils down to diligence, vigilance and personal accountability. At Cox, each technician has a periphery duty, including tool calibration. The individual assigned to tool calibration uses the same maintenance control software program that is deployed for the aircraft (Computerized Aircraft Maintenance Program, aka CAMP). Along with managing calibration with exceptional accuracy, it is front and center every time there is a status check on the aircraft. TRACKING TOOLS WITH RFID TECHNOLOGY Radio-frequency identification (RFID) “is one of many enabling technologies – but only when integrated thoughtfully into a complete system,” said Chwan. Snapon has developed hybrid approaches that combine RFID, machine vision, digital imaging, electronic locks and database traceability to suit different environments and tool types. The key is not simply tracking tools but connecting that data into workflow systems that improve decision-making, reduce downtime and strengthen compliance. 16 CIVIL AND MUNICIPAL VOLUME 06, ISSUE 12
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